Case Study: Shell Global Solutions achieves advanced elastohydrodynamic lubricant simulations with COMSOL Multiphysics

Shell Global Solutions - Customer Case Study

Shell Global Solutions faced the challenge of predicting elastohydrodynamic lubrication in highly loaded contacts—pressures up to 3–4 GPa, sub-micron films, extreme shear rates and a need to model varying rheology (including viscoelastic grease). Their legacy proprietary direct solver worked for simpler, smooth-surface cases but was hard to modify and struggled with the increased geometric/physical complexity, so the team turned to Comsol (COMSOL Multiphysics) to address these more demanding simulations.

Using Comsol, Shell Global Solutions implemented coupled multiphysics models that reproduce Reynolds/elastic-deformation interactions and, where needed, solve the full Navier–Stokes equations with viscoelastic models for grease and time-dependent loading. Comsol delivered the same benchmark results as Shell’s in-house solver while enabling larger, rough-surface meshes (≈1,000 nodes for a 3 mm contact), easier model development with no coding, and robust stabilization strategies for high-pressure contacts—expanding Shell’s ability to analyze gear teeth and rolling-element bearings and accelerate ongoing research.

Shell Global Solutions

Robert Ian Taylor

Technology Manager